Apparatus for treating a surface of a double-faced corrugated unit

ABSTRACT

A method and apparatus are provided for treating one surface of a double-faced corrugated unit, such as fiberboard, so as to render the latter more responsive to vacuum pressures when said unit is as a substrate in combination with a heat-softened film during formation of a skin-pack-type package. In utilizing the instant method only one surface of the unit is perforated and then coated with a suitable material whereby the heat-softened film can be readily responsive to the vacuum pressures exerted on the unit and at the same time become securely bonded to the substrate. The perforating and coating steps are accomplished expeditiously during one pass of the unit through the apparatus.

ite ties Fiscer et a1.

[72] inventors: John P. Fischer, East Grand Rapids; Vern 1R. Kahler, Grandville, both of Mich.

Packaging Corporation 01 America, Evanston, 111.

[22] Filed: Nov.24,1969

[21] Appl.No.: 879,193

[73] Assignee:

Iwaniw ..118/46 2,347,227 4/1944 Wilgus v.118/46 244,845 7/1881 Bowlcs. .....83/1 17 3,552,244 l/l97l Smith 83/116 X FOREIGN PATENTS OR APPLICATIONS 259,835 10/1926 Great Britain ..l18/37 Primary Examiner-John P. McIntosh Attorney-Pendleton, Neuman, Williams & Anderson [57] ABSTRACT A method and apparatus are provided for treating one surface of a double-faced corrugated unit, such as fiberboard, so as to render the latter more responsive to vacuum pressures when said unit is as a substrate in combination with a heat-softened film during formation ofa skin-pack-type package. In utilizing the instant method only one surface of the unit is perforated and then coated with a suitable material whereby the heat-softened film can be readily responsive to the vacuum pressures; exerted on the unit and at the same time become securely bonded to the substrate. The perforating and coating steps are accomplished expeditiously during one pass of the unit through the apparatus.

2 Claims, 3 Drawing Figures PATENIEDJANZSISIZ 3535918 IN VEUToIP5 JOHN P. FISCHER Vemv A. KAHLER 5% P5 UDLE To M, Med/MAI SE/BOLD fll/zLLm/xs I47T0M5 APPARATUS FOR TREATING A SURFACE OF A DUUBILTZ-IFACED COUGATED UNIT BACKGROUND OF THE INVENTION general public as an efficient and attractive way of merchan' dising said products. Basically in forming such a package the product is initially subtended and supported. by a substrate which is substantially inflexible and yet has sufficient porosity to permit a vacuum pressure to be drawn therethrough. Draped over the supported product and the adjacent supporting surface of the substrate is a heat-softened film which, when the vacuum pressure is drawn through the substrate, will snugly envelop the product and become bonded to the substrate surface. ll-Ieretofore, in undertaking such packaging it was found that (a) the porosity of the substrate had to be substantially uniform in order for the film to properly envelop the product and become secure to the substrate, (b) in addition to the substrate having a substantially uniform porosity, it was important that the bond coating applied to the substrate supporting surface be of uniform consistency and density and not impair the finished appearance of the package, and (c) it was necessary that the substrate be of a sturdy yet inexpensive material.

In the forming of a suitable substrate for this purpose, it was customary that a carefully selected coating was applied to the substrate supporting surface prior to the latter being perforated. In following such a procedure, it was found that a considerable period of time was normally required between the coating and perforating steps in order to avoid the perforating equipment becoming fouled by the coating material.

As a result of the time lapse, the two steps were normally performed by either two separate pieces of equipment, or, if perfon'ned by a single piece of equipment, necessitated the substrate making two passes through the equipment. The net result of such substrate manipulations was that the formation of the substrate often become an awkward and time-consuming operation. Furthermore, the equipment required in performing the various steps was normally costly and complex and required frequent adjustment.

SUMMARY OF THE INVENTION Thus, it is an object of this invention to provide apparatus for treating in a simple and inexpensive way a double-faced corrugated unit so as to render same suitable for use as a substrate in a skin-pack-type package.

It is a further object of this invention to provide an apparatus which greatly facilitates and expedites the production of double-faced corrugated units for use as substrates in a skin-pack-type package.

It is a still further object of this invention to provide apparatus whereby a wide variety of coating materials may be utilized as a coating for the substrate.

Further and additional objects will appear from the description, accompanying drawings, and appended claims.

In accordance with one embodiment of this invention an apparatus is provided which comprises a spiked roller having the exterior thereof provided with a plurality of outwardly and radially projecting spikes arranged in roller-encircling, axially spaced rows. Carried by the roller and disposed between predetermined rows of spikes are resilient roller-encircling ribs. The height of each rib, when in a noncompressed state, is substantially the same as the extent to which the spikes project from the roller. During perforating of one surface of the substrate by the rows of spikes, the portions of the ribs adjacent the perforating spikes are compressed and in frictional engagement with the one surface of the substrate. A backup roller cooperates with and is spaced from the spiked roller. The spacing between the rollers is greater than the extent to which the spikes project and thus, as the substrate passes between the rollers only one exposed surface of the substrate is perforated. Upon leaving the roller, the perforated substrate is moved past a coating means whereupon an adhesive coating is applied to the perforated surface of the substrate.

DESCRIPTiON For a more complete understanding of the invention reference should be made to the drawing wherein:

FIG. 1 is a fragmentary, diagrammatic view of one form of the improved apparatus.

FIG. 2 is an enlarged. fragmentary perspective view of the spiked roller and backup roller therefor and showing a doublefaced corrugated substrate passing therebetween.

HO. 3 is a fragmentary perspective view of the spiked roller.

Referring now to the drawing and more particularly to FIG. 11, one form of the improved apparatus 10 is shown which is adapted to perforate, coat, and print one exposed surface of a substrate 11. The substrate in the illustrated embodiment is double-faced corrugated fiberboard which includes a pair of liners 11a and b and a corrugated liner lllc sandwiched therebetween.

The perforating of the substrate whereby only one of the liners 11a thereof is perforated is performed by a spiked roller or drum 12 working in combination with a first backup roller 13. The spiked roller is power driven to rotate about a horizontal axis in a counterclockwise direction, as seen in FIG. 1. Secured to the exterior of roller 12 is a sleeve 14! preferably formed of metal, which carries a plurality of spikes or studs 15. The spikes extend radially outwardly a short distance through suitable openings 14a formed in the sleeve. The distal end 15a of each spike 15 is pointed so as to facilitate penetration of the substrate liner 11a. The spikes, in the illustrated embodiment, are arranged in axially spaced, roller-encircling rows A, B, C, and D. The number and spacing between the rows of spikes will depend upon the perforated design desired on the substrate liner lllla. Disposed intermediate predetermined rows of spikes are resilient, roller-encircling ribs 16. The height of the ribs is approximately the same as the extent to which the spikes 15 project radially outwardly from the roller 12. Thus, when the spikes are in contact with the substrate liner 11a, portions of the ribs adjacent the liner-contacting spikes are compressed and in frictional engagement with the substrate liner 11a, see FIG. 2. The number of ribs and the spacing between same may vary, as desired, and will depend primarily upon the width of the substrate being perforated. In any case, it is preferred that the substrate be simultaneously engaged by at least two ribs so that the substrate will be positively driven forwardly by the driven spiked roller 12. Furthermore, the rubs assure positive contact between the backup roller 13 and the underside of the substrate while the latter is being perforated.

The backup roller is normally of a smaller diameter than roller 12 and has a smooth exterior surface which is in substantial tangential contact with the substrate underside. The axes of roller 12 and 13 are parallel and in vertical alignment with respect to one another. The spacing between the exterior surfaces of rollers 12 and 13 is greater than the projection of spikes 15 so that the spikes will not perforate liner 11b which is in contact with roller 13.

Subsequent to the substrate 11 passing between rollers 12 and i3, it is moved horizontally and passes between a coating roller 17 and a second backup roller 18. The rollers 17 and 18 are of conventional design and a continuous or patterned coating of thermoplastic adhesive/cohesive primer is applied to the exposed perforated surface of liner 11a. The chemical composition and the thickness of the applied coating will be selected for optimum compatibility with the film to be subsequently used in the skin-packing operation.

In lieu of the coating roller 17 and backup roller I8, a spraying apparatus, not shown, may be employed for applying the Subsequent to passing from between rollers 17 and 18 the substrate may pass between a printer roller 20 and a third backup roller 21. Printer roller 20 is of conventional design and will apply the desired indicia on the perforated, coated, exposed surface of the liner 11a. If the liner 11a has been printed prior to being assembled to form the double-faced corrugated substrate, the printer roller 20 and backup roller 21 may be omitted. In addition toapplying the indicia to the exposed surface of liner 11a, printer roller 20 may be provided with suitable attachments so as to efi'ect scoring, slitting, and/or slotting of the substrate. In any case, the perforating, coating, printing, scoring, slitting, and slotting can be accomplished by a single pass of the substrate through the apparatus. With the improved apparatus, the speed of the substrate therethrough is approximately 800 lineal feet per minute. Such a substrate speed is substantially greater than that experienced with prior methods and apparatus. The sequence of the perforating and coating steps are such that no problems occur with respect to the perforating mechanism becoming fouled with the coating material. The improved method embodies techniques well known in the papermaking art and eliminates or substantially reduces manual effort previously involved in treating such a substrate,

While the term double-faced corrugated unit has heretofore been used to describe the substrate 11, it is to be noted, however, that this term is intended to include various other types of multiply constructions.

We claim:

1. An Apparatus for treating one surface of double-faced corrugated unit while the latter is moving in a given direction, said apparatus comprising a spiked roller having the exterior thereof provided with a plurality of outwardly projecting spikes, a predetermined number of which are arranged in roller-encircling rows, and a plurality of annular resilient ribs disposed intermediate predetermined rows of spikes, the height of said ribs, when in a noncompressed state, being substantially the same as the extent of projection of said spikes, said ribs having portions thereof in compressed frictional engagement with a unit surface liner when the latter is in substantial tangential relation with said spiked roller and is being perforated by adjacent spikes; and backup means spaced from said spiked roller and between which the moving unit passes, the spacing between said roller and backup means being greater than the extent to which said spikes project from said spiked roller, said resilient ribs effecting positive contact of said backup means by the moving corrugated unit; and coating means disposed downstream of said roller and backup means for coating the perforated surface of the moving unit.

2. The apparatus of claim 1 including printer means disposed downstream of said coating means and being adapted to apply indicia on said perforated coated surface of the moving corrugated unit. 

2. The apparatus of claim 1 including printer means disposed downstream of said coating means and being adapted to apply indicia on said perforated coated surface of the moving corrugated unit. 